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Sm00620 Tds-4 Manual
Sm00620 Tds-4 Manual
Sm00620 Tds-4 Manual
SM00620
Revision B
March 8, 2001
ii
TDS-4S Contents
Contents
Book 1 Description
Preface/Manual conventions
Safety information ........................................................... 1-5
Directional references ...................................................... 1-6
Manual layout.................................................................. 1-6
Chapter 1 Introduction
General description .......................................................... 1-7
TDS-4S Contents
iii
March 8, 2001
Chapter 3 Specifications
Drilling motor ......................................................... 1-65
Main gearbox lube system ........................................ 1-65
Cooling systems ....................................................... 1-66
Local blower ...................................................... 1-66
Derrick mounted remote blower ........................ 1-66
Closed loop ........................................................ 1-66
Guide dollies ............................................................ 1-67
Pipehandler .............................................................. 1-67
Service loop kits ....................................................... 1-68
Power loop (non-regulated areas) ....................... 1-68
Control loop ...................................................... 1-68
Fluid loop .......................................................... 1-69
Electrical equipment accessories ............................... 1-70
API Class I, Division II -N.E.C. ........................ 1-70
European standard zone 2 area-EExd ................. 1-70
iv
TDS-4S Contents
Chapter 1 Preparation
Preinstallation checklist.................................................... 2-7
Chapter 2 Installation
Derrick electrical termination kit ..................................... 2-9
Installation ................................................................. 2-9
Wiring ..................................................................... 2-13
Plumbing ....................................................................... 2-15
Hydraulic................................................................. 2-15
Air ........................................................................... 2-15
Water....................................................................... 2-15
Rig-up procedure ........................................................... 2-16
Counterbalance system .................................................. 2-21
Motor alignment cylinder system ................................... 2-22
Drillers controls and instrumentation ........................... 2-23
Varco Drillers Console (VDC)................................ 2-23
Throttle and torque limit controls ........................... 2-23
Wiring ..................................................................... 2-23
Service loops .................................................................. 2-24
Installation ............................................................... 2-24
Electrical loop .................................................... 2-25
Fluids loop ......................................................... 2-25
Air loop ....................................................... 2-26
Retract loop ....................................................... 2-27
Chapter 3 Commissioning
Checkout procedures ..................................................... 2-29
Long term TDS storage procedures................................ 2-32
Returning the TDS to service after storage ..................... 2-33
TDS-4S Contents
March 8, 2001
Book 3 Operation
Preface/Manual conventions
Safety information ........................................................... 3-5
Directional references ...................................................... 3-6
Manual layout .................................................................. 3-6
vi
TDS-4S Contents
Chapter 1 Maintenance
Inspection ........................................................................ 4-9
TDS swing out procedure .......................................... 4-9
DC drilling motor ................................................... 4-12
Motor alignment cylinder ........................................ 4-12
Air exhaust muffler .................................................. 4-12
Derrick termination kit air filter/regulator/
lubricators ................................................................ 4-13
Pipehandler .............................................................. 4-14
Nondestructive Examination (NDE) ....................... 4-14
Visual inspection................................................ 4-14
Landing collar .............................................. 4-16
Drive stem ................................................... 4-18
Magnetic Particle Inspection (MPI) ................... 4-20
Ultrasonic Inspection ......................................... 4-21
Safety valve inspection procedures (IBOP) ... 4-21
Chapter 2 Lubrication
Lubricating the motor and motor support
bonnet assembly............................................................. 4-23
Gearbox ................................................................... 4-23
Torque setting procedure ................................... 4-25
Other gearbox lubrication and
maintenance considerations ............................... 4-27
Initial oil change period ........................................... 4-27
Oil capacity.............................................................. 4-28
Lubricating the DC motor ....................................... 4-29
Lubricating the washpipe and bonnet seal ................ 4-30
Lubricating the rotating head ......................................... 4-31
Lubricating the link adapter ........................................... 4-32
Lubricating the torque wrench ....................................... 4-33
Lubricating the master bushing ID wear guide ............... 4-34
TDS-4S Contents
vii
March 8, 2001
Chapter 3 Maintenance
Adjustment procedures .................................................. 4-49
Adjusting the torque wrench .................................... 4-49
Adjusting the upper safety valve (IBOP)
and safety valve actuator system ............................... 4-52
Adjusting the counterbalance system ........................ 4-52
Adjusting the motor alignment cylinder system ....... 4-54
Precharging the counterbalance system .................... 4-60
Assembly and disassembly .............................................. 4-62
Pipehandler .............................................................. 4-62
Torque wrench disassembly ............................... 4-62
Replacing the torque wrench
clamping piston seal ..................................... 4-68
Replacing the standard rotating head
glyd rings ........................................................... 4-71
Replacing the powered rotating head
glyd rings ........................................................... 4-75
Replacing the standard or extended reach
link tilt air actuator ............................................ 4-77
Removing the tong dies ........................................... 4-81
Front jaw ........................................................... 4-81
Rear jaw ............................................................. 4-81
Removing the jaws ................................................... 4-82
Front jaw ........................................................... 4-82
Rear jaw ............................................................. 4-82
Upper safety valve (IBOP) ....................................... 4-82
Lower safety valve (IBOP) ....................................... 4-82
Removing the motor assembly
from the guide dolly....................................................... 4-83
Disassembly/assembly of the drilling motor
and motor support bonnet ....................................... 4-84
Installing the TDS motor pinion ................................... 4-87
Local blower cooling system assembly/disassembly ... 4-89
Closed loop cooling system assembly/disassembly .... 4-92
Replacing the safety wiring ............................................ 4-95
Safety wiring tips ..................................................... 4-97
viii
TDS-4S Contents
Chapter 4 Troubleshooting
Troubleshooting the counterbalance .............................. 4-99
Troubleshooting the motor alignment cylinder ...... 4-100
Troubleshooting the drilling motor and guide dolly ..... 4-101
Troubleshooting the motor air brake ..................... 4-101
Troubleshooting the retract guide dolly ................. 4-101
Troubleshooting the transmission .......................... 4-102
Troubleshooting the oil pump ............................... 4-103
Troubleshooting the cooling system ....................... 4-104
Troubleshooting the pipehandler ................................. 4-106
Troubleshooting the torque wrench ....................... 4-106
Troubleshooting the safety valve actuator............... 4-108
Troubleshooting the link tilt .................................. 4-108
Troubleshooting the pipehandler at the
counterbalance manifold ........................................ 4-109
Troubleshooting the crown height indicator .......... 4-110
Six-gang air valve assembly illustration ................... 4-111
TDS-4S Contents
ix
March 8, 2001
TDS-4S Contents
TDS-4S
Top Drive
Drilling
System
Description
SM00620-1
Rev. B
March 8, 2001
1-2
TDS-4S Description
Contents
Preface/Manual conventions
Safety information ........................................................... 1-5
Directional references ...................................................... 1-6
Manual layout.................................................................. 1-6
Chapter 1 Introduction
General description .......................................................... 1-7
TDS-4S Description
1-3
March 8, 2001
Chapter 3 Specifications
Drilling motor ......................................................... 1-65
Main gearbox lube system ........................................ 1-65
Cooling systems ....................................................... 1-66
Local blower ...................................................... 1-66
Derrick mounted remote blower ........................ 1-66
Closed loop ........................................................ 1-66
Guide dollies ............................................................ 1-67
Pipehandler .............................................................. 1-67
Service loop kits ....................................................... 1-68
Power loop (non-regulated areas) ....................... 1-68
Control loop ...................................................... 1-68
Fluid loop .......................................................... 1-69
Electrical equipment accessories ............................... 1-70
API Class I, Division II -N.E.C. ........................ 1-70
European standard zone 2 area-EExd ................. 1-70
1-4
TDS-4S Description
Preface
Manual conventions
Safety information
Information pertaining to possible personnel injury and
equipment damage appears throughout this manual and is
formatted to draw the readers attention to important
information, a warning, or a caution note. See the examples
below and pay close attention to these important advisories.
z
e
TDS-4S Description
1-5
March 8, 2001
Directional references
References to the right or left and front or back of components
described in this manual assume the perspective of the Top Drive
Drilling System (TDS-4S), standing behind the TDS-4S as it
faces well center.
Manual layout
This binder contains several separate books that you can remove
individually for convenience.
1-6
TDS-4S Description
Chapter 1
Introduction
General description
Oil well drilling with a rotary table, kelly drive bushing, and a 45
ft. kelly was the industry standard for years. For decades, drillers
extended the drill string with the making-a-single-connection
process using the rotary table, kelly, pipe tongs, drawworks
cathead, master bushing, bowls, and slips. This method of
handling pipe and joint makeup remained unchanged, apart from
minor improvements such as kelly spinners, until the advent of
top drive drilling systems.
Varco produces several Top Drive Drilling Systems (TDS) to
rotate the drill string and allow adding entire 93 ft. stands of pipe,
eliminating two thirds of the conventional single-pipe drilling
connections. This manual describes the function and
maintenance of the TDS-4S, which integrates the drill pipe
connection handling and drive systems with the drilling swivel.
The TDS (Figures 1-1 and 1-2) provides the rotating power of a
conventional rotary table drive while eliminating the need to
pick up the cumbersome swivel/kelly combination. The TDS
does not interfere with the existing conventional equipment. It
allows tripping, circulation, rotation, and the running of casing as
well as providing 90 ft. back reaming capabilities to reduce the
chance of stuck pipe.
TDS-4S Description
1-7
March 8, 2001
Guide Dolly
Assembly
Motor Housing
Assembly
LO
Pipehandler Assembly
1-8
TDS-4S Description
Gooseneck
Air Brake
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Bonnet
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Swivel Bearing
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Bull Gear
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DC Drilling Motor
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Standard
Washpipe Packing
Upper Gearcase
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Low Gear
(Engaged)
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High Gear
(Disengaged)
Rotating Head
Main Shaft/Drive Stem
Lower Gearcase
TDS-4S Description
1-9
March 8, 2001
1-10
TDS-4S Description
Rotating Head
(Part of the Motor Housing Assembly)
Link Adapter
(Also know as: Solid Body Elevator)
(Landing Collar Inside
on Main Shaft/Drive Stem)
Hydraulic/Pneumatic
Link Tilt
Upper IBOP
Valve Actuator
Splined Upper
IBOP Valve
Lower IBOP Valve
(Inside Torque Tube)
Torque Wrench
Manually or
Remotely Operated
Drill Pipe Elevator
(Optional Varco Equipment)
TDS-4S Description
1-11
March 8, 2001
650-Ton
Rotating Head
(Part of Motor
Housing Assembly)
Link Adapter
(Also known as
Solid Body Elevator)
(Landing Collar Inside
On Main Shaft/Drive Stem)
Torque Wrench
108 in.
350-Ton Links
(Optional Varco Equipment)
Manually or Remotely
Operated Drill Pipe Elevator
(Optional Varco Equipment)
1-12
TDS-4S Description
Main Shaft/
Drive Stem
Link Adapter
(Also known as
Solid Body Elevator)
Landing Collar
Upper IBOP
Valve Actuator
Air Cylinder (2)
Safety Valve
Actuator Shell
Upper IBOP
Torque Tube
Lower IBOP
Saver Sub
Drill Pipe
1-13
March 8, 2001
The drive stem passes through the link adapter. The torque
arrestors keep the link adapter above the landing collar on the
drive stem when drilling (Figures 1-6, 1-7 and 1-8). When
hoisting, the link adapter is pulled down onto the landing collar
due to the added weight of the drill string. This directs the
hoisting load through the drive stem, motor housing assembly,
and swivel bail.
The fluid service loop provides the hydraulic, pneumatic power,
and optional cooling water services to the TDS. The electric
service loops provide DC power and AC power/control.
A drill pipe elevator hangs from a pair of conventional links that
attach to the link adapter. Actuating the link tilt swings the
elevator out to facilitate picking up pipe.
The Major component description chapter of this book describes
each of these assemblies. Subsequent books provide more
information on the equipment specific to your rig configuration.
1-14
TDS-4S Description
Rotating Head
(Part of Motor Housing Assembly)
Link Adapter
(Also known as
Solid Body Elevator)
Torque
Arrestors (4)
Figure 1-6. 650-Ton rotating head, link adapter and torque arrestors
TDS-4S Description
1-15
March 8, 2001
650/500-Ton
Rotating Head
(Part of
Motor Housing
Assembly)
650/500-Ton
Link Adapter
(Also known as
Solid Body
Elevator)
Torque
Arrestor
650-Ton: (4)
500-Ton: (2)
Link Adapter
Support Plate
Upper
IBOP Valve
108 in.
350-Ton
Links
(Optional
Varco Equipment)
Safety Valve
Actuator
Torque Wrench
Lower
IBOP Valve
Saver Sub
1-16
TDS-4S Description
650-Ton
Rotating Head
(Part of Motor
Housing
Assembly)
650-Ton
Link Adapter
(Also known as
Solid Body
Elevator)
Torque
Arrestor (4)
Link Adapter
Support Plate
Upper
IBOP Valve
108 in.
350-Ton
Links
(Optional
Varco
Equipment)
Safety Valve
Actuator
Torque Wrench
Lower
IBOP Valve
Saver Sub
TDS-4S Description
1-17
March 8, 2001
1-18
TDS-4S Description
Chapter 2
Major component
description
TDS-4S Description
1-19
March 8, 2001
Drilling motor
The drilling motor on the TDS is a 1,100 hp DC drilling motor.
Mechanically, the motor features a double-ended armature shaft
and thrust bearings for vertical operation.
There is an air brake on the motor to hold torque in the drill
string to assist in directional work. It is remotely operated by a
solenoid valve. Please refer to the specifications included later in
this book for additional details.
1-20
TDS-4S Description
Rotating Head
Assembly
Shifter
Input Shaft
LO
HI
External
HI / LO
Indicator
Compound
Gear Shafts
Bottom View
Low Gear
Eccentric Shaft
(Disengaged)
High Gear
Eccentric Shaft
(Engaged)
Geneva
Mechanism
Shifter Input
Top View
TDS-4S Description
1-21
March 8, 2001
1-22
TDS-4S Description
Lower Radial
Shaft Bearing
Motor Pinion
Gears
Side View
Bull
Gears
Inlet
Bull Gears
Motor Pinion
Gears
LEGEND
Pressure Tap
Fabricated
Drilled
Bottom View
1-23
March 8, 2001
1-24
TDS-4S Description
Cam
Stationary Flange
Cam Follower
Locking Lever
Auto-Return
Cylinder
Torque Arrestor
Location
Glyd Ring (8)
Swivel Block
Torque Wrench Hanger
(Lug not shown)
TDS-4S Description
1-25
March 8, 2001
TDS-4S Description
Stationary
Flange
Rotary Glyd
Ring (11)
Bull Gear
Torque Arrestor
Hanger
Swivel Block
A5
H1
S2
A2
H3
PRESSU
A3
RE
A1
S1
H1
Hydraulic Motor
Assembly
S2
H2
A4
A1
A4
A5
A2
H3
A3
H2
S1
TDS-4S Description
1-27
March 8, 2001
Cooling systems
Local blower
The local blower cooling system with an optional extended intake
provides local cooling air to the drilling motor (Figure 1-13). It
receives air approximately 27 ft. above the rig floor at the lowest
point of the motors travel.
An explosion-proof 20 hp, 3,450 rpm AC electrical motor
directly drives the impeller in the blower housing. An optional
flexible duct connects the blower housing to the extended intake
mounted on the traveling equipment.
Two spark arrestor assemblies are mounted on the exhaust ports
of the upper gearcase. These components hinder the egress of any
air born sparks from the DC motor.
1-28
TDS-4S Description
Axial Fan
20 hp
Blower Motor
Transmission
Cooler
Locking Key
Oil Fittings (2)
Blower Housing
Gasket
Mounting
Brackets (2)
Blower Impeller
Taper Lock
Bushing
Gasket
Flex Duct
Connection
Point
Mounting Plate
Blower Duct to
AC Drilling Motor
Spark Arrestor
TDS-4S Description
1-29
March 8, 2001
Closed loop
The closed loop cooling system (Figure 1-14) consists of two air/
water heat exchangers cooled by twin blowers driven by a double
ended AC motor. Ducting directs air out the motor exhaust port
to the heat exchangers and back to the blower inlets. The heat
exchangers are built from Cupro-Nickel tubes and the headers are
pressure tested to 250 psi.
The system requires a supply of liquid coolant (sea water, chilled
fresh water or glycol) at 100 gpm at a maximum inlet
temperature of 90F.
Purge air at a rate of 70 scfm per motor at 1.0 psig is also required
to provide positive system pressure, and a purge control system
(refer to TDS Control System information provided later in this
chapter) monitors system pressure to insure safe operation.
1-30
TDS-4S Description
Dual Shaft
20 hp AC
Blower Motor
Blower Mount/
Brake Cover
Blower
Housing (2)
Impeller (2)
8 in. Flex
Connection (2)
Water
Connections
DC to Motor
Exhaust Port on
Upper Gear Case
Inspection
Cover
GE
Drilling Motor
Heat Exchanger (2)
TDS-4S Description
1-31
March 8, 2001
Remote blower
The remote blower motor cooling system consists of a motor and
pressure blower mounted in the derrick at racking board level
(Figure 1-15). Air is drawn in from outside the wind wall,
through a flexible duct into the top of the drilling motor, and
exits through spark arrestors attached to the air outlets of the
motor.
A pressure switch monitors the motor air inlet pressure to verify
blower operation. The contacts of the pressure switch are usually
wired into the SCR assignment logic for the drilling motor.
A moisture separator is attached to the blower inlet duct to
prevent water from entering the motor.
1-32
TDS-4S Description
Air Inlet
40 hp Explosion Proof
Electric Motor (AC)
and Centrifugal
Pressure Blower
Wind Wall
Racking Platform
at Racking Board Level
Spark Arrestor
TDS-4S Description
1-33
March 8, 2001
1-34
TDS-4S Description
Motor Frame
Hold-down Bolt
(Swing Bolt) (2)
TDS-4S Description
1-35
March 8, 2001
Guide Dolly
Frame
Retract
Cylinder
Lower
Extend/Retract
Arm
LEGEND
Intermediate
Frame
45.0"
1-36
TDS-4S Description
Extended Mode
Retracted Mode
Motor Alignment
Cylinder
Shipping
Brace
Motor
Frame Dolly (Ref)
TDS-4S Description
1-37
March 8, 2001
Pipehandler
The main components of the pipehandler include the following
(Figures 1-3 and 1-4):
Link adapter
Safety valves (Upper and Lower IBOPs)
IBOP valve actuator
Torque wrench
Link tilt mechanism
The pipehandler provides two basic functions for the TDS:
Tripping 93 ft. drilling pipe stands
Providing up to 85,000 ft lb torque for makeup and
break-out of connections at any height in the derrick
(the PH-60d provides up to 60,000 ft lb torque)
The pipehandler can be configured for various tool joint
connections. It includes a link adapter and a special-purpose
Varco torque wrench assembly. It also incorporates a remote
IBOP valve actuator and link tilt mechanism.
When not in use, the pipehandler remains stationary and free
from the drill string passing through it. When tripping or
performing bottom hole operations, the pipehandler is free to
rotate 360, emulating the action of a standard hook.
1-38
TDS-4S Description
Link adapter
The link adapter (solid body elevator) and the elevator links
(Figures 1-7 and 1-8), working in conjunction with the torque
arrestors, transfer the hoisting loads to the drive stem.
The drive stem is free to rotate inside the link adapter while
drilling. The link adapter does not rotate with the drive stem
because torque arrestors raise the link adapter up off the load
supporting landing collar located on the drive stem.
When hoisting loads, springs inside the torque arrestors compess
to transfer the load to the drive stem by pulling the link adapter
down onto the landing collar. The link adapter rotates with the
rotating headwhich is required for tripping operations.
The torque arrestors contain compression springs capable of
supporting any stand of drill pipe in the full up position.
TDS-4S Description
1-39
March 8, 2001
Saver subs are load bearing components in the TDS and must be
inspected periodically along with other load bearing components.
Refer to the Maintenance and Troubleshooting book for more
information.
TDS-4S Description
Main Shaft/
Drive Stem
Link Adapter
(Also known as
Solid Body Elevator)
Landing Collar
Upper IBOP
Valve Actuator
Air Cylinder (2)
Safety Valve
Actuator Shell
Upper IBOP
Torque Tube
Lower IBOP
Saver Sub
Drill Pipe
TDS-4S Description
1-41
March 8, 2001
Torque wrench
The torque wrench provides a means for making and breaking
out connections with the drive stem.
The torque wrench assembly consists of the following
components (Figures 1-20 and 1-21):
Hanger
Torque tube
Torque tube guide ring
Two torque cylinders
Two clamping jaws
Two clamping pistons
Control manifold
Lift cylinder
Two stop tubes
Stabbing guide
IBOP actuator cylinders and arms
TDS-4S Description
IBOP Actuator
Hoses (Air)
Hanger
Torque Wrench
Hoses (Hydraulic)
IBOP Actuator
Air Cylinders
Lift Cylinder
IBOP
Actuator Arms
Torque Tube
Clamping Jaw
(Inside Clamp Body)
V
a
r
c
o
Control Manifold
(Hidden)
Torque Cylinder (2)
Stabbing Guide
Clamping Piston
(Inside Clamp
Body Cylinder)
Guide Ring
(Not Visible)
TDS-4S Description
1-43
March 8, 2001
IBOP Actuator
Hoses (Air)
Hanger
Torque Wrench
Hoses (Hydraulic)
Lift Cylinder
IBOP Actuator
Air Cylinders
IBOP
Actuator Arms
Torque Tube
Stop Tube (2)
Clamping Jaws
(Inside Clamp Body)
Control Manifold
(Hidden)
Torque Cylinder (2)
Stabbing Guide
Clamping Piston
(Inside Clamp
Body Cylinder)
Guide Ring
(Not Visible)
1-44
TDS-4S Description
TDS-4S Description
1-45
March 8, 2001
Lifting Frame
Intermediate
Stop
Air
Actuator
D/P Elevator
Link Clamp
Intermediate
Stop Release
1-46
TDS-4S Description
Lifting
Frame
Double Air
Actuator
D/P Elevator
Link Clamp
Intermediate
Stop
Intermediate
Stop Release
TDS-4S Description
1-47
March 8, 2001
1-48
TDS-4S Description
Hydraulic
Link Tilt with
Passive Stop
Passive
Stop
Assembly
(2)
Cylinder
Assembly
(2)
Link
Tilt Arm
Hydraulic
Link Tilt with
Intermediate Stop
Intermediate
Stop
Stop
Adjuster
TDS-4S Description
1-49
March 8, 2001
Elevator links
Varco elevator links attach to the link adapter and support the
drill pipe elevator. Elevator link options include:
108 in., 350-Ton elevator links
132 in., 350-Ton elevator links
180 in., 500-Ton elevator links (special long links for running
casing, providing 120 in. of clearance for cementing heads)
1-50
TDS-4S Description
Counterbalance system
The counterbalance system prevents damage to tool joint threads
while making or breaking connections with the TDS. It provides
cushioned stroke similar to that provided by the hook.
The counterbalance system prevents damage to the threads of the
saver sub and drill pipe by offsetting the weight of the top drive
while stabbing into a connection. The system (Figure 1-27)
consists primarily of two hydraulic cylinders, a counterbalance
manifold, and two hydraulic accumulators. The hydraulic
cylinder assemblies connect the integrated swivel bail and the
traveling equipment (hook, block, becket, hook adapter, etc.).
When properly adjusted, the counterbalance system supports all
but about 800 lb of the weight of the top drive over a full 8 to
10 in. of travel.
The system also incorporates a complete backup. The two
accumulators, constantly maintained at system pressure, are
always able to provide pressure to the counterbalance cylinders if
the HPU is off or non-operational for any reason. For normal
operation, however, the HPU is on when using the torque
wrench for breaking out the top drive at the floor and is left on
while making up the next stand.
When adding a stand to the string during drilling operations, the
driller takes a stand in the elevators and stabs it into the box in
the rotary table. The driller continues to lower the TDS until the
saver sub touches the box of the new stand. At this point, only
about 800 lb load is on the saver sub/drill pipe connection. The
counterbalance cylinders support the remainder of the TDS
weight. The driller then spins in and torques up the connection
with the pipehandler assembly and is ready to drill ahead.
Note that the driller does not have to do anything extra to get the
counterbalance system to function properly. It is a pre-adjusted
system. Once drilling resumes, the HPU can be turned off and
restarted again for breaking out the connection at the floor after
drilling the stand down.
TDS-4S Description
1-51
March 8, 2001
Stabbing Mode:
Top Drive Lowered Past Thread Contact
Guide Dolly
Assembly
18,970 lb
18,970 lb
Hydraulic
Cylinders (2)
Hydraulic
Accumulators (2)
38,750 lb
Typical System Weight
Counterbalance
Manifold
810 lb
Weight on Threads
Hydraulic
Power Supply
Fluids
Service Loop
Rig Floor
1-52
TDS-4S Description
TDS-4S Description
1-53
March 8, 2001
1-54
TDS-4S Description
Service loops
The service loops transfer the required electric and fluid services
between the derrick service standpipes and junction boxes, and
the corresponding junction boxes and fluid connections located
on the TDS. There are two kinds of loops: one containing the
electric cables, and one containing air, hydraulic and water lines
(water lines included only on units with a closed loop cooling
system).
The power electrical loop contains four 646 MCM DC power
cables, one 2/0 AWG drilling motor ground cable. The other
electrical service loop contains a composite cable consisting of:
26 14 AWG conductors for auxiliary features
4
The power and ground cables are spiral wound and potted inside
a protective cover with 7 1/2 in. mounting flanges at each end.
The composit cable is pathed in its own smaller service loop. This
allows for easy changeout of either the power loop or the
composit loop in the event of a failure.
The TDS can use optional dual electrical service loops in order to
meet certain regulatory agency requirements for power cable
current carrying capacity.
The fluids loop can consists of any combination of the following:
3
TDS-4S Description
1-55
March 8, 2001
1-56
TDS-4S Description
Auxiliary equipment
Auxiliary equipment is compatible with all TDS models. All of
the equipment is selected or adapted for your specific rig. Below is
a list of auxiliary equipment available:
Master bushing ID wear guide
Swiveling drill collar dolly
Wireline adapter
Crown height indicator
Drillers recorder tranducer kit
TDS-4S Description
1-57
March 8, 2001
1-58
TDS-4S Description
A
100 TON
VARCO
Drill Collar
Dolly
Perfection
Links (36")
;;;
;;;
;;
;;; ;;
;;;
91 in.
Square
Shoulder
Elevator
Lifting
Sub
37 in.
8 in.
Drill
Collar
View
A-A
TDS-4S Description
1-59
March 8, 2001
Wireline adapter
The wireline adapter (Figures 1-28 and 1-29) attaches to the
pipehandler and prevents wireline from interfering and damaging
pipe and TDS components. It can be used with a lubricator held
in the elevators by using 180 in. casing elevator links.
42.52 in.
26.0 in.
23.1 in.
1-60
TDS-4S Description
View A-A
Top Drive
Torque Wrench
20 in. Dia.
Sheave
Elevator Links
(180 in. longCustomer furnished)
Lubricator
To Mud Manifold
Elevator Links
(180 in. or longerCustomer furnished)
View A-A
TDS-4S Description
1-61
March 8, 2001
1-62
TDS-4S Description
CROWN CLEARANCE
2 FEET
WHEN FLASHING
IBOP
CLOSE
BRAKE
ON
IBOP
CLOSE OPEN
BRAKE
OFF ON
TORQ. WRENCH
PUSH & PULL
LINK TILT
OFF ON
R
5 FEET
Y
10 FEET
ACTIVE/TEST
Integrated Controls
IBOP
CLOSE
BRAKE
ON
CROWN CLEARANCE
2 FEET WHEN FLASHING
Purge Air in
R
5 FEET
IBOP
CLOSE OPEN
BRAKE
OFF ON
Y
10 FEET
TORQ. WRENCH
PUSH & PULL
LINK TILT
OFF ON
ACTIVE/TEST
VDC
Independent
Controls
TDS-4S Description
1-63
March 8, 2001
1-64
TDS-4S Description
Chapter 3
Specifications
Drilling motor
Horsepower: 1,100
Maximum stall time at full power is generally about 10 seconds.
Refer to the Operation book for details.
TDS-4S Description
1-65
March 8, 2001
Cooling systems
Local blower *
Flow
3,200 cfm
Blower motor
20 hp
Typical voltage
Speed
3,450 rpm
Spark arrestors
3,200 cfm
Blower motor
40 hp
Typical voltage
Speed
3,450 rpm
Spark arrestors
Closed loop
1-66
TDS-4S Description
Flow
3,200 cfm
Blower motor
20 hp
Typical voltage
Speed
3,450 rpm
Heat exchanger
220,000 BTU/Hr.
for GE motor
Oil cooler
6 gpm
90F
Guide dollies
Standard rail setback
30, 39 or 48 in.
(Wellcenter to centerline of rails)
Standard rail spacing
(Centerline of rails)
62, 66 or 72 in.
Roller size
Frame material
Pipehandler
Break-out torque
Hydraulic pressure
Hydraulic flow
30 to 35 gpm
Air pressure
90 psi minimum
TDS-4S Description
1-67
March 8, 2001
4 (each)
Standard length
Diameter
Ground cable
1-68
TDS-4S Description
Fluid loop
Size
3,000 psi
Size
Working pressure
150 psi
3,500 psi
Size
Working pressure
150 psi
2,000 psi
Size
Working pressure
150 psi
1,625 psi
Size
3,000 psi
TDS-4S Description
1-69
March 8, 2001
Cast aluminum,
explosion proof
Cast aluminum,
explosion proof
Various switches
Torque meter
(0 - 1,500 Amps)
RPM meter
(0 - 350 rpm)
Stainless steel
Stainless steel
1-70
TDS-4S Description
50,000
LOW GEAR
45,000
160 RPM
40,000
37,200 INTERMITTENT
1,130 HP LIMIT
35,000
32,500 CONTINUOUS
30,000
25,000
HIGH GEAR
20,000
15,000
12,000 ft lb
10,000
5,000 ft lb
5,000
120
190
0
0
50
100
150
200
250
300
RPM
CONTINUOUS TORQUE VALUES ARE BASED ON 1250 ARMATURE AMPS
INTERMITTENT TORQUE VALUES ARE BASED ON STALL AT 1400 AMPS
WITH A 7 SEC. MAX. DURATION
JUNE 3, 1991 A.N.
TDS-4S Description
1-71
March 8, 2001
55,000
50,000
50,100
INTERMITTENT
45,000
45,500
CONTINUOUS
LOW GEAR
40,000
35,000
32,000 INTERMITTENT
30,000
29,100 CONTINUOUS
HIGH GEAR
25,000
20,000
Reduced Field
Required in this Area
15,000
10,000
5,000
130 RPM
205 RPM
0
0
50
100
150
200
250
300
RPM
Continuous Torque Values are based on 1250 Armature Amps.
Intermittent Torque Values are based on stall at 1400 Amps with a 7 second maximum duration.
Reduced Field area is based on a 30 Amps Field.
1-72
TDS-4S Description
TDS-4S
Top Drive
Drilling
System
Installation and
Commissioning
SM00620-2
2-2
Contents
Preface/Manual conventions
Safety information ........................................................... 2-5
Directional references ...................................................... 2-6
Manual layout.................................................................. 2-6
Chapter 1 Preparation
Preinstallation checklist.................................................... 2-7
Chapter 2 Installation
Derrick electrical termination kit ..................................... 2-9
Installation ................................................................. 2-9
Wiring ..................................................................... 2-13
Plumbing ....................................................................... 2-15
Hydraulic................................................................. 2-15
Air ........................................................................... 2-15
Water....................................................................... 2-15
Rig-up procedure ........................................................... 2-16
Counterbalance system .................................................. 2-21
Motor alignment cylinder system ................................... 2-22
Drillers controls and instrumentation ........................... 2-23
Varco Drillers Console (VDC)................................ 2-23
Throttle and torque limit controls ........................... 2-23
Wiring ..................................................................... 2-23
Service loops .................................................................. 2-24
Installation ............................................................... 2-24
Electrical loop .................................................... 2-25
Fluids loop ......................................................... 2-25
Air loop ....................................................... 2-26
Retract loop ....................................................... 2-27
Chapter 3 Commissioning
Checkout procedures ..................................................... 2-29
Long term TDS storage procedures................................ 2-32
Returning the TDS to service after storage ..................... 2-33
2-3
2-4
Preface
Manual conventions
Safety information
Information pertaining to possible personnel injury and
equipment damage appears throughout this manual and is
formatted to draw the readers attention to important
information, a warning, or a caution note. See the examples
below and pay close attention to these important advisories.
z
e
2-5
Directional references
References to the right or left and front or back of components
described in this manual assume the perspective of the Top Drive
Drilling System (TDS-4S), standing behind the TDS-4S as it
faces well center.
Manual layout
This binder contains several separate books that you can remove
individually for convenience.
2-6
Chapter 1
Preparation
Preinstallation checklist
The following assumes that all preinstallation planning and rig-up
has been accomplished prior to installation of the TDS. This
includes:
1. Guide rails and bracing are installed and inspected to
conform to Varco specification and installation tolerances
(Figures 2-1, 2-2, and 2-3).
2. Stops are ready for installation at the bottom of the rails.
3. Hydraulic and air standpipes are installed in the derrick,
flushed clean, and pressure tested. Water piping is installed,
flushed, and pressure tested as well for configurations with
closed loop cooling systems.
4. All electronics are installed up to the derrick junction box:
DC power leads, AC leads for blower motor, and control/
alarm signals.
5. The transfer panel is installed.
6. Rigging of the tong lines, etc. are inspected to ensure that
they will not foul with the TDS and other rig equipment.
2-7
2-8
Chapter 2
Installation
2-9
1/4 in.
CL Rail
CL Rail
3/8 in. Over Full Length
1/8 in. Within 25 ft. of Floor
CL Rail
CL Rail
C
L Well Center
C
L Well Center
TDS Back
Operational Clearance Between Top Drive
And Nearest Girt or Fastline Should Be 3 in. Minimum
Guide Rails
Nearest Girt
Splice
Clearance
Splice Plates
or Bolts Are
Not Permissible
on Inside
Surfaces
of Beam
Dolly Overhang
Guide
Dolly
Config.
Rail
Size
39 x 66
48 x 62
30 x 72
30 x 72
W14 x 90
W14 x 90
W12 x 90
W14 x 90
Drill Floor
CL Well Center
2-10
Splice
Dolly
Clear
Overhang
Inches
3.3
3.3
3.3
2.3
0
0
1.6
0.5
Instrument
J-Box **
Electrical Supply*
Motor J-Box **
Filter/Regulator
Lubrication Assembly**
48.0 in.
800 lb Load
B
18.0 in.
Must Support
4,000 lb
Hydraulic
Air Standpipes
Standpipes
To Be 1 1/2 in.
To Be 1 1/2 in. Sch 40 Pipe*
Sch 80 Pipe*
Water Standpipes
A
To Be 2 in.
Sch 40 Pipe*
86 ft.
Service
Loops
36.0 in.
View A-A
Typical Service
Loop Termination
Gussets *
75 ft.
Mud
Hose
Ref
Service Loop
Bracket**
Existing Girt *
5500 lb Load
View B-B
83 ft. Hydraulic, Air and Water
Standpipe Height and
Service Loop Bracket Location
10 ft. 6 in.
+0/-4 in.
7 ft. Ref
* Customer Supplied
** Varco Supplied
2-11
Motor Frame
Setback
Rails
L
P
7 ft. TDS-3S
8 ft. TDS-4S,
TDS-6S, TDS-8S
P
L
Rail Stops
L
42,600 lb for a typical TDS-3S
48,000 lb for a typical TDS-4S
52,000 lb for a typical TDS-7S
48,000 lb for a typical TDS-8S
TDS-3S
TDS-4S, TDS-8S
39 in. x 66 in.
18,600
18,900
48 in. x 62 in.
18,600
18,900
30 in. x 72 in.
17,500
17,800
TDS-7S
5450
--
3090
3680
5800
--
3290
3170
5000
--
2840
--
3330
3780
--
Rail Spacing
TDS-3S
39 in. x 66 in.
3450
48 in. x 62 in.
30 in. x 72 in.
91/101 in. x 108 in.
TDS-4S, TDS-8S
2-12
Wiring
The electrical installation requires routing power to the transfer
panel and then to the TDS through the service loops (Figure 2-4).
In addition, control cables are required between the service loop,
the transfer panel, the SCR, the TDS Varco Drillers Console
(VDC), the SCRs drillers console, the hydraulic and water
pumps and the drilling recorder.
Derrick
Power
J-Box
Transfer Panel
#12AWG/20C
#10AWG/4C
#14AWG/2 Pr Shld
#6AWG/2C*
Shunt Field
Derrick
AC
J-Box
(4)646MCM*
Top
Drive
System
AC
Power
HYD
Pump
#2
#16AWG/10C
#16AWG/10C
Existing
Drillers Console
#16AWG/10C
#10AWG/4C
#10AWG/4C
#6AWG/4C
#6AWG/4C
TDS
Drillers Console
HYD
Pump
#1
Rotary
Table
RBS
Controls
#12AWG/3C
E/P
RPM
#6AWG/2C*
Existing
Power
Cables
#16AWG/10C
E/P
Torq
#14AWG/2 Pr Shld
#12AWG/3C
#14AWG/37C
#12AWG/20C
#12AWG/20C
#16AWG/10C
#12AWG/20C
#10AWG/4C
#14AWG/2 Pr Shld
#12AWG/3C
SCR
Room
Service Loop
#6AWG/2C*
Shunt Field
#16AWG/10C
Water
Pump
#1
Water
Pump
#2
2-13
Runs
646MCM (4 Shunt)
(8 Series)
#6AWG/4C
#10AWG/4C
#12AWG/20C
#12AWG/3C
#14AWG/37C
#14AWG/2PR SHLD
#16AWG/10C
#16AWG/10C
#14AWG/2PR SHLD
Plumbing
The plumbing connections should terminate near the service loop
bracket. The mating halves are preassembled on the service loop.
Specifications for specific lines are described in the following
sections.
Hydraulic
Hydraulic lines should be cleaned and pickled, black pipe lines
(one pressure and one return) 1 1/2 or 2 in. schedule 80 pipe.
Install shut-off valves at the drill floor or racking board level. The
derrick connections are reduced to 1 in. NPT female pressure and
fluid return for connection to the service loop.
Air
Air lines should be schedule 40, 1 or 1 1/2 in. pipe in the case of
the purge supply for the TDS. Install a shut-off valve at drill floor
or racking board level. The air lines connect to the filtered and
lubricated supply. The derrick connections are reduced to 1 in.
NPT female for the purge line (if required) and 1/2 in. for the air
line in order for the fluids service loop to match.
Do not connect purge air lines to the lubricator. Only use clean,
dry air in the purge air system.
Water
The two cooling lines should be schedule 40, 2 in. pipe. Install
shut-off valves at the drill floor or racking board level. See the
cooling system specifications for water supply requirements. The
derrick connections are reduced to 1 1/4 in. NPT female pressure
and return for connection to the fluids service loop.
2-15
Rig-up procedure
z
2-16
O-Ring
Split Landing
Collar (2)
Drive Stem
2-17
2-18
Pear Link
Connecting
Link
Hydraulic
Accumulator
(Inside Motor Frame)
Motor Frame
and Guide Dolly
Assembly
Counterbalance
Cylinder Assembly
(2)
Counterbalance
Manifold
(On Guide Dolly)
Counterbalance Lug
(Bolted to Bail)
Integrated
Swivel Bail
2-19
Loop Assembly
Guide Assembly
Cylinder Assembly
Hose Assemblies
Hydraulic Accumulator
(Inside Dolly Tube)
Swivel Bail
Counterbalance
Operation Switch
2-20
Never operate the top drive with the exhaust duct covers
attached to the spark arrestors on the air exhaust ducts.
Doing so severely restricts air flow through the motor, causing
overheating and potential damage. They can also fall off
during operation and injure personnel working below.
Attach the covers only during shipping and storage.
Counterbalance system
Figures 2-6 and 2-7 illustrates the installation arrangement for
this system. Please see the Maintenance and Troubleshooting book
for the adjustment procedures.
This assembly is pre-charged when it is shipped by land or water
transport. When this assembly is shipped by air freight, it must be
pre-charged according to the instructions in the Maintenance and
Troubleshooting book.
2-21
Motor Alignment
Cylinder
Shipping
Brace
Motor
Frame Dolly (Ref)
2-22
Wiring
Refer to the electrical schematics in the engineering drawings.
2-23
Service loops
Installation
Install the service loops as follows:
1. Fabricate the appropriate brackets and clamps to attach the
service loop mounting bracket to the derrick structure.
2. Place the service loop derrick mounting bracket at the height
specified on the derrick interface drawing provided in the
engineering drawings. Locate the bracket on the side of the
derrick adjacent to the hinges on the TDS and as far as
practical toward the corner where the guide rail bracing is
attached. The bracket must be located far enough from the
corner to insure the loops do not catch under the guide rails
during operations, but far enough back to provide clearance
for tong lines, the stabbing board, tugger lines, etc.
3. Do not unpack the service loops from the shipping protective
crate until they are ready to hang in the derrick. Lift the
service loops onto the rig floor (still in the crates) and then
remove them from the crates with the lifting eyes provided.
2-24
7. Pick up the TDS end of the loops and attach them to the
service loop bracket at the bottom of the motor frame.
8. Complete the terminations of the two loops as outlined in the
following sections.
Electrical loop
1. Connect the pre-terminated wire ends at the motor J-boxes
using the appropriate glands. Refer to the electrical schematic
provided to ensure proper terminal block assignments.
2
Fluids loop
1. Before connecting the hoses from the service loop, be certain
that the service stand pipes have been flushed free of any
contamination.
2-25
The hoses in the fluids loop only extend 11 ft. from the
mounting bracket. It may be necessary to make jumper hoses to
reach the standpipes.
Air loop
2-26
Retract loop
If your rig is equipped with a retract guide dolly, attach the retract
loop to the derrick mounting brackets as follows:
There are four separate service loops needed for a TDS with
retractable dollies: two electrical loops, a fluids loop, and a retract
system loop. The electrical and fluids service loops attach to the
derrick service loop mounting bracket, the retract loop attaches to
the retract system service loop bracket.
1. Lift the crate containing the retract system service loop onto
the rig floor.
2. Uncrate the service loop.
3. Attach an air winch to the lifting eyes on the derrick end
(derrick end has 8 ft. of hose extending beyond the flange)
and hoist to the retract system mounting bracket.
4. Attach the service loop flange to the mounting bracket with
the hardware provided. Ensure that the service loop hangs
straight in the derrick without any twists or kinks.
Before connecting the hoses from the service loop, be certain that the
standpipes have been flushed free of any contamination.
2-27
2-28
Chapter 3
Commissioning
Checkout procedures
1. Turn on the hydraulic and air power and check for leaks.
Repair as required.
2. Turn on the electric power (drillers controls only).
3. Check the function of switches and solenoids. There is an
audible click when each solenoid is actuated.
4. Actuate the link tilt. Be sure that it operates smoothly and the
elevator reaches a joint in the mousehole.
5. Adjust the intermediate stop so that the elevator clears the
monkeyboard when actuated. Refer to the Maintenance and
Troubleshooting book if a problem occurs.
6. Actuate the motor brake. There is a loud sound as the air
escapes when the brake releases.
7. Move the Make/Break valve located on the manifold at the back
of the pipehandler torque wrench to the BREAK position.
8. Turn on the hydraulic power supply and adjust the pressure
reducing valve (also located on the torque wrench manifold)
to the appropriate pressure for the lower IBOP connection.
2-29
2-30
24. Bring the TDS down as if stabbing the saver sub into the box.
The pin and box should be in alignment. If adjustment is
necessary, use the following procedure:
a. Measure how far and in what direction (toward or away
from the rails) the pin must move to line up with the drill
pipe box.
b. Turn off the HPU and bleed down the cylinder
accumulator (open the needle valve on the back of the
manifold). This allows the motor alignment cylinder to
relax and the motor to rotate on its trunnions until the
integrated swivel bail contacts the motor support bonnet.
c. Loosen the lock tab and jam nut on the cylinder clevis.
d. With a wrench tightened on the cylinder rod flats, screw
the rod into or out of the clevis, in the same direction the
saver sub pin is to be moved.
e. Secure the jam nut and lock tab.
f. The nominal position of the two cylinder flow control
valves is 1-1/2 turn off their seats. If you experience heavy
drill pipe vibration, first attempt to control it with nonrotating stabilizers if the casing shoe is close to the surface.
If motor movement becomes excessive due to continued
vibration, (more than 1/2 in. of total cylinder stroke)
close the flow controls to 3/4 turn off their seats.
2-31
2-33
2-34
TDS-4S
Top Drive
Drilling
System
Operation
SM00620-3
3-2
TDS-4S Operation
Contents
Preface/Manual conventions
Safety information ........................................................... 3-5
Directional references ...................................................... 3-6
Manual layout.................................................................. 3-6
TDS-4S Operation
3-3
3-4
TDS-4S Operation
Preface
Manual conventions
Safety information
Information pertaining to possible personnel injury and
equipment damage appears throughout this manual and is
formatted to draw the readers attention to important
information, a warning, or a caution note. See the examples
below and pay close attention to these important advisories.
z
e
TDS-4S Operation
3-5
Directional references
References to the right or left and front or back of components
described in this manual assume the perspective of the Top Drive
Drilling System (TDS-4S), standing behind the TDS-4S as it
faces well center.
Manual layout
This binder contains several separate books that you can remove
individually for convenience.
3-6
TDS-4S Operation
Chapter 1
Operating procedures
Start-up procedure
Use the following procedure to start up the TDS:
1. Place the blower/oil pump switch in the AUTO position.
2. Place the hydraulic power unit (HPU) switch in the PLC
position.
3. Place the water pumps switch in the PLC position.
4. Place the motor space heater switch in the ON position.
5. Place the top drive/rotary table (TDS/ROT) lockout switch
in the TDS position.
6. Assign a SCR.
TDS-4S Operation
3-7
The brake on the top end of the TDS drilling motor armature shaft is
a static, or parking brake. It is not a running or dynamic brake. It is
not intended to, nor is it capable of, slip-releasing the wind-up torque
in the drill string. Using the brake to slip-release the drill string
wind-up torque causes the brake to heat up and can destroy the brake
lining.
When the TDS motor brake holds the down-hole torque, Varco
recommends using the following procedure to safely release the
torque in the string:
1. Use the hand throttle to develop motor torque equal to the
wind-up torque held by the parking brake.
2. Release the parking brake.
3. Reduce the drill current, reducing motor torque, as the drill
string slowly releases the wind-up torque.
4. Turn the hand throttle off and reset the drill current to the
normal operating position after the pipe unwinds completely.
3-8
TDS-4S Operation
Amps
280
470
670
820
240
90
45
30
900
1000
1200
1400
25
20
15
10
TDS-4S Operation
3-9
Rotating Head
Assembly
Shifter
Input Shaft
LO
HI
External
HI / LO
Indicator
Compound
Gear Shafts
Bottom View
Low Gear
Eccentric Shaft
(Disengaged)
High Gear
Eccentric Shaft
(Engaged)
Geneva
Mechanism
Shifter Input
Top View
3-10
TDS-4S Operation
Pipehandler operation
Standard rotating head
The perimeter of the rotating head cam (Figure 3-2) has an
indented area where the cam follower normally rests. When the
cam follower is in this indented area, the return cylinder rod is
fully retracted and hydraulic pressure inside the cylinder is at
equilibrium. When the swivel block and cam rotates to another
position along with the drill string, the ramp of the cam extends
the return cylinder rod, unbalancing hydraulic pressure in the
cylinder. When the elevator is released, the system automatically
returns to its pre-selected (indented) position (equilibrium).
To operate the swivel block locking mechanism, pull down the
locking lever, pulling the locking pin out of one of 24 locking
slots in the cam. With the locking lever in the vertical position,
manually rotate the swivel block to the desired position and
release the locking lever, setting the pin.
Cam
Stationary Flange
Cam Follower
Locking Lever
Auto-Return
Cylinder
Torque Arrestor
Location
Glyd Ring (8)
Swivel Block
Torque Wrench Hanger
(Lug not shown)
TDS-4S Operation
3-11
Controls
The powered rotating head is controlled by two switches.
ROTATING HEAD LEFT/RIGHT switch
This switch rotates the powered rotating head, pipe handler, and
link tilt to the right or left (same direction as the drill string).
Rotation only occurs when the switch is held in the RIGHT or
LEFT position. Rotation stops when the switch returns to the
center position.
3-12
TDS-4S Operation
Stationary
Flange
Rotary Glyd
Ring (11)
Bull Gear
Torque Arrestor
Hanger
Swivel Block
A5
H1
S2
A2
H3
PRESSU
A3
RE
A1
S1
H1
Hydraulic Motor
Assembly
S2
H2
A4
A1
A4
A5
A2
H3
A3
H2
S1
TDS-4S Operation
3-13
3-14
TDS-4S Operation
Main Shaft/
Drive Stem
Link Adapter
(Also known as
Solid Body Elevator)
Landing Collar
Upper IBOP
Valve Actuator
Air Cylinder (2)
Safety Valve
Actuator Shell
Upper IBOP
Torque Tube
Lower IBOP
Saver Sub
Drill Pipe
TDS-4S Operation
3-15
Torque wrench
The primary function of the TDS torque wrench is to breakout
the drill string from the saver sub before making a connection.
The torque wench can also make connections if necessary (i.e.,
when replacing the lower IBOP or saver sub, or while backreaming, or when adding a pup joint to the drill stem).
The torque wrench has a control manifold with the following
components (Figure 3-5):
Hydraulic pressure gauge
Control and sequencing valves
Hydraulic hose inlet and outlet Quick Disconnects (QDs)
Manual Make/Break directional valve
The Make/Break valve controls the torque wrench operating
direction (makeup/breakout) during operation.
A pressure reducing valve (PRV) on the control manifold allows
presetting the makeup torque (this valve is bypassed when the
torque wrench is in breakout mode).
When the driller actuates the torque wrench from the VDC, the
lifting cylinder rod retracts, raising the torque tube to engage the
splines on the upper IBOP. A sequenced signal from the control
manifold then operates the clamping piston, clamping the jaws
onto the drill string box connection. Then another sequenced
signal from the control manifold automatically
directs pressure to the torque cylinders, rotating the torque tube
up to 25 while developing a maximum torque of 85,000 ft lb
(65,000 ft lb on the PH-60d Pipehandler). The position of the
Make/Break valve on the control manifold determines the
direction that the torque tube rotates.
A two-position, air-piloted, hydraulic valve located on the
counterbalance manifold located on top of the TDS guide dolly
controls the entire sequenced cycle described above. A push
button switch on the VDC operates the hydraulic valve. The
driller holds the button down to makeup or breakout a
connection, and then releases the button to allow the torque
wrench to automatically recycle to the ready position. If the
torque developed on the first pass is insufficient, the driller simply
operates the button again.
3-16
TDS-4S Operation
Make/Break
Valve
Recycle
Sequence
Valve
Clamp
Sequence
Valve
Torque
Sequence
Valve
Torque Wrench
Manifold
BREAK
MAKE
Hydraulic
Pressure
Return
RECYCLE
CLAMP
TORQUE
PRV
50
60
40
30
1000
1500
70
80
Hydraulic
Pressure
Inlet
20
LIFT LOWER
500
2000
90
10
2500
PSI
Ft.Lbs.
10
0
Lift/Lower
Flow Control
Valve
x1000
Torque Gauge
0 - 2500 PSI
TDS-4S Operation
3-17
3-18
TDS-4S Operation
5 1/2 F.H.
95497-A-H-N-*-*
95497-A-J-N-*-*
NC 38
91873-650
91873-650
94731-650
94731-650
94730-650
95497-A-K-N-*-*
91873-651
94730-651
95497-B-K-N-*-*
95497-A-L-N-*-*
91873-651
n/a
n/a
94730-652
TBD
6 5/8 F.H.
2 7/8 F.H.
94729-650
94729-651
94729-652
97219-651
n/a
PH-60d
To operate the torque wrench with a 3 1/2 in. drill string, install a
separate drill string handling kit. The following lists available kits
for a PH-60d:
Part No. 78652-1 Includes stabbing guide assembly, jaw
assemblies, saver subs, installation drawing.
Part No. 78652-2 Includes stabbing guide assembly, jaw
assemblies, installation drawing.
Part No. 78652-1 includes 3 1/2 IF saver subs, while Part No.
78652-2 does not. By purchasing the latter, the user assumes
responsibility for obtaining appropriate 6 5/8 reg. x 3 1/2 IF saver
subs separately. Specifications for these are available from the
factory or any Varco service center.
TDS-4S Operation
3-19
ID
Connection
OD
Upper IBOP to
main stem/main shaft
3 or 3 3/4 in.
50,000 ft lb
63,000 ft lb
3 or 3 3/4 in.
50,000 ft lb
60,000 ft lb
Saver sub to
lower IBOP valve
3 or 3 3/4 in.
46,000 ft lb
60,000 ft lb
Crossover sub to
lower IBOP valve
3 or 3 3/4 in.
46,000 ft lb
60,000 ft lb
3 or 3 3/4 in.
9 in.
83,000 ft lb
91,000 ft lb
3 or 3 3/4 in.
9 in.
75,000 ft lb
84,000 ft lb
Saver sub to
lower IBOP valve
3 or 3 3/4 in.
66,000 ft lb
85,000 ft lb
Crossover sub to
lower IBOP valve
3 or 3 3/4 in.
75,000 ft lb
91,000 ft lb
3-20
TDS-4S Operation
9 in.
Drilling ahead
Drilling ahead with triples
Drilling ahead with triples is the common drilling mode for the
TDS. There are various sources for triples. On skidding rigs
drilling multiple well platforms, drill pipe can be left racked and
used to drill the next well.
If triples do not currently exist, there are two recommended
methods of obtaining them. One is to leave some triples racked in
the derrick when tripping back in the hole and finish the trip
with singles. Leave enough triples racked to handle anticipated bit
life.
The second method for obtaining triples is to make up triples in
the mousehole while drilling ahead or during idle rig time. For
safety reasons a pivoting mousehole is best because it can pivot to
a vertical plane to simplify making connections.
Use the following procedure to drill ahead with triples
(Figure 3-6):
1. Drill down until the saver sub is within three feet of the
rotary table.
2. Circulate bottoms up as necessary.
3. Stop the string rotation.
4. Pick up the string and set slips for a connection four feet off
the rig floor.
5. Switch the TDS motor from FORWARD to REVERSE.
6. Stop the mud pumps.
7. Close the IBOP.
8. Break out the drill pipe connection using the torque wrench
on the pipehandler.
9. Using the TDS motor, spin out of the box while hoisting the
TDS with the drawworks (follow with the drawworks, do not
lead).
TDS-4S Operation
3-21
Set slips on
string
Stop circulation
Raise block
Tilt link tilt
to derrickman
Breakout
connection
using pipehandler
and drilling motor
(in reverse)
Lower block to
stab motor into
top of stand
Pull slips
Spin in motor
and stand
Begin drilling
Start circulation
Makeup both
connections with
motor
1
Link
Tilt
Makeup
Start
Circulation
Stop
Circulation
Stab
Makeup
3-22
TDS-4S Operation
TDS-4S Operation
3-23
3-24
TDS-4S Operation
Set slips on
string
Tilt links to
mousehole
Stop circulation
Close IBOP
Stab bottom of
single onto string
Lower block to
stab motor into
top of single
Pull slips
Spin in motor
and single
Start circulation
Open IBOP
Begin drilling
Makeup both
connections with
motor in
torque mode
Breakout
connection
using pipehandler
and drilling motor
(in reverse)
Makeup
Open
IBOP
Close
IBOP
Link
Tilt
Stab
Makeup
TDS-4S Operation
3-25
TDS-4S Operation
Pickup string
10 to 20 ft.
Stop circulation
Set slips
Raise block
Spin in stand
Pull slips
Extend RBS
and adjust height
Makeup both
connections
with motor
Retract RBS
Unlatch elevator
Breakout/spinout
with pipehandler
and motor
Start circulation
Pickup stand
Begin drilling
90 ft.
Makeup
Start
Circulation
Stop
Circulation
Makeup
TDS-4S Operation
3-27
Tripping
Perform tripping operations in the conventional manner. Use the
link tilt feature to tilt the elevator to the derrickman so the
derrickman can quickly latch it around the pipe.
The hydraulic link tilt allows the elevator to also reach the
mousehole.
The air actuated link tilt has an intermediate stop which is
adjustable to set the elevator at a convenient working distance
from the monkeyboard. The intermediate stop tilts out of the way
to allow the elevator to reach the mousehole.
If a tight spot or key seat is encountered while tripping out of the
hole, spin the drilling motor into the stand at any height in the
derrick. Establish circulation and rotation immediately to work
the pipe through the tight spot.
3-28
TDS-4S Operation
Reaming out
The TDS permits reaming out of an open hole to prevent pipe
sticking and to reduce key seat formation, without affecting
racking functions associated with normal tripping (i.e., there are
no singles to contend with). The pipehandler torque wrench can
break out 90 ft. stands in the derrick.
Use the following procedure to ream out of the hole (Figure 3-9):
1. Hoist the block while circulating and rotating the drilling
motor until the third connection appears.
2. Stop circulation and rotation and set the slips.
3. Break out the drilling motor from the top of the stand using
the pipehandler torque wrench. Hold a backup at the floor
and spin out the drilling motor.
4. Break out the stand at floor level, and spin out using pipe
spinners.
5. Pick up the stand with the drill pipe elevator.
6. Rack the stand back.
7. Lower the block and TDS to the floor.
8. Stab the drilling motor into the box, spin up and torque it
with the drilling motor. With light slip loads, the pipehandler
torque wrench can be used to torque the connection.
9. Resume circulation and continue reaming out of the hole.
TDS-4S Operation
3-29
Hoist while
circulating and
rotating
When 3rd
connection
surfaces, stop
rotation and
circulation
Set slips on
string
Setback stand
using link tilt
Spin in motor
and makeup
connection with
motor
Breakout and
spinout stand
at floor
Start circulation,
pull slips,
hoist and rotate
Lower block,
stab motor into
string
Breakout
Hoist
Setback
Hoist and
Rotate
Breakout
3-30
TDS-4S Operation
TDS-4S Operation
3-31
Running casing
For casing operations, longer elevator links (180 in.) must be used
to allow clearance for the cementing head under the torque
wrench in the pipehandler.
Attach a short piece of hose to the saver sub in the pipehandler to
fill the casing while lowering. Use the remotely controlled upper
IBOP valve to start and stop the fluid flow.
If desired, run casing conventionally using the block and hook
and swinging the TDS aside. Use longer bails (180 in.) to prevent
the block dolly (if used) from contacting the TDS dolly.
3-32
TDS-4S Operation
A
Drill Pipe
Elevator
A
100 TON
VARCO
Drill Collar
Dolly
Perfection
Links (36")
;;;
;;;
;;
;;; ;;
;;;
91 in.
Square
Shoulder
Elevator
Lifting
Sub
37 in.
8 in.
Drill
Collar
View
A-A
TDS-4S Operation
3-33
3-34
TDS-4S Operation
TDS-4S
Top Drive
Drilling
System
Maintenance
and
Troubleshooting
SM00620-4
Rev. B
March 8, 2001
4-2
Contents
Preface/Manual conventions
Safety information ........................................................... 4-7
Directional references ...................................................... 4-8
Manual layout.................................................................. 4-8
Chapter 1 Maintenance
Inspection ........................................................................ 4-9
TDS swing out procedure .......................................... 4-9
DC drilling motor ................................................... 4-12
Motor alignment cylinder ........................................ 4-12
Air exhaust muffler .................................................. 4-12
Derrick termination kit air filter/regulator/
lubricators ................................................................ 4-13
Pipehandler .............................................................. 4-14
Nondestructive Examination (NDE) ....................... 4-14
Visual inspection................................................ 4-14
Landing collar .............................................. 4-16
Drive stem ................................................... 4-18
Magnetic Particle Inspection (MPI) ................... 4-20
Ultrasonic Inspection ......................................... 4-21
Safety valve inspection procedures (IBOP) ... 4-21
Chapter 2 Lubrication
Lubricating the motor and motor support
bonnet assembly............................................................. 4-23
Gearbox ................................................................... 4-23
Torque setting procedure ................................... 4-25
Other gearbox lubrication and
maintenance considerations ............................... 4-27
Initial oil change period ........................................... 4-27
Oil capacity.............................................................. 4-28
Lubricating the DC motor ....................................... 4-29
Lubricating the washpipe and bonnet seal ................ 4-30
Lubricating the rotating head ......................................... 4-31
Lubricating the link adapter ........................................... 4-32
Lubricating the torque wrench ....................................... 4-33
Lubricating the master bushing ID wear guide ............... 4-34
TDS-4S Maintenance and Troubleshooting
4-3
March 8, 2001
Chapter 3 Maintenance
Adjustment procedures .................................................. 4-49
Adjusting the torque wrench .................................... 4-49
Adjusting the upper safety valve (IBOP)
and safety valve actuator system ............................... 4-52
Adjusting the counterbalance system ........................ 4-52
Adjusting the motor alignment cylinder system ....... 4-54
Precharging the counterbalance system .................... 4-60
Assembly and disassembly .............................................. 4-62
Pipehandler .............................................................. 4-62
Torque wrench disassembly ............................... 4-62
Replacing the torque wrench
clamping piston seal ..................................... 4-68
Replacing the standard rotating head
glyd rings ........................................................... 4-71
Replacing the powered rotating head
glyd rings ........................................................... 4-75
Replacing the standard or extended reach
link tilt air actuator ............................................ 4-77
Removing the tong dies ........................................... 4-81
Front jaw ........................................................... 4-81
Rear jaw ............................................................. 4-81
Removing the jaws ................................................... 4-82
Front jaw ........................................................... 4-82
Rear jaw ............................................................. 4-82
Upper safety valve (IBOP) ....................................... 4-82
Lower safety valve (IBOP) ....................................... 4-82
Removing the motor assembly
from the guide dolly....................................................... 4-83
Disassembly/assembly of the drilling motor
and motor support bonnet ....................................... 4-84
Installing the TDS motor pinion ................................... 4-87
Local blower cooling system assembly/disassembly ... 4-89
Closed loop cooling system assembly/disassembly .... 4-92
Replacing the safety wiring ............................................ 4-95
Safety wiring tips ..................................................... 4-97
4-4
Chapter 4 Troubleshooting
Troubleshooting the counterbalance .............................. 4-99
Troubleshooting the motor alignment cylinder ...... 4-100
Troubleshooting the drilling motor and guide dolly ..... 4-101
Troubleshooting the motor air brake ..................... 4-101
Troubleshooting the retract guide dolly ................. 4-101
Troubleshooting the transmission .......................... 4-102
Troubleshooting the oil pump ............................... 4-103
Troubleshooting the cooling system ....................... 4-104
Troubleshooting the pipehandler ................................. 4-106
Troubleshooting the torque wrench ....................... 4-106
Troubleshooting the safety valve actuator............... 4-108
Troubleshooting the link tilt .................................. 4-108
Troubleshooting the pipehandler at the
counterbalance manifold ........................................ 4-109
Troubleshooting the crown height indicator .......... 4-110
Six-gang air valve assembly illustration ................... 4-111
4-5
March 8, 2001
4-6
Preface
Manual conventions
Safety information
Information pertaining to possible personnel injury and
equipment damage appears throughout this manual and is
formatted to draw the readers attention to important
information, a warning, or a caution note. See the examples
below and pay close attention to these important advisories.
z
e
4-7
March 8, 2001
Directional references
References to the right or left and front or back of components
described in this manual assume the perspective of the Top Drive
Drilling System (TDS-4S), standing behind the TDS-4S as it
faces well center.
Manual layout
This binder contains several separate books that you can remove
individually for convenience.
4-8
Chapter 1
Maintenance
Inspection
TDS swing out procedure
Varco top drives with swing-out guide dollies can be quickly
swung aside on their own dolly frames for inspection,
maintenance, running casing, or to allow drilling operations
requiring a kelly and rotary table. Electrical, hydraulic, and air
supplies do not have to be disconnected. Use the following
procedure to swing out the TDS only if your rig has a guide dolly
with hinge pins (refer to the engineering drawings for
information specific to your rig configuration):
1. If you have a retract system, operate the switch on the VDC
to retract the TDS.
2. Slowly lower the TDS until the elevator nears the rig floor.
3. Remove the elevator and elevator links.
4. Lower the TDS guide dolly to the stop.
4-9
March 8, 2001
Unlatching the hook from the integrated swivel bail may cause the
TDS motor assembly and/or the hook to lurch suddenly. Always
keep adequate tension on the tailing lines to prevent sudden
movement of these assemblies.
9. Unlatch the hook.
10. Attach tugger lines to the TDS motor frame, opposite the
frame hinges, to assist in swinging out the TDS motor
assembly. Use tailing lines on the motor frame to control
swing out.
11. Unfasten the two swing-out bolts, opposite the hinges,
holding the motor frame to the guide dolly.
12. Operate the air tuggers to slowly pull on the motor frame
while unhooking the traveling block from the swivel bail.
13. When the traveling block is disconnected, continue swinging
out the TDS 180 and secure the motor assembly to the
derrick with chain and/or rope.
4-10
While latching the hook to the integrated swivel bail, the swivel
and/or the TDS motor assembly may suddenly lurch. Always keep
adequate tension on tailing lines to prevent sudden movement of
these assemblies.
3. Attach tugger lines to the TDS motor assembly, opposite the
hinges, to aid in swinging back the TDS assembly. Use tailing
lines on the motor frame to control swing back.
4. Release the chain and/or rope securing the TDS motor
assembly to the derrick and slowly swing back the TDS motor
assembly to the guide dolly. While swinging it back, latch the
hook onto the swivel.
5. Secure the motor frame to the guide dolly with the two
swing-out bolts opposite the hinges.
6. Connect the mud hose to the S-tube.
7. Connect the air intake hose.
8. Hook the counterbalance system pear links onto the ears of
the hook or block.
9. Turn the HPU on and bleed air out of the system.
4-11
March 8, 2001
DC drilling motor
Thoroughly inspect the TDS, motor support bonnet, and guide
dolly assembly for loose bolts and fittings daily. If any safety wire
or cotter pins were removed to facilitate repairs, replace them
immediately.
4-12
4-13
March 8, 2001
Pipehandler
Thoroughly inspect the pipehandler for loose bolts and fittings
daily. If any safety wire or cotter pins were removed during
repairs, replace them immediately.
Inspect the hinge bolts daily to make sure they are not separating
from the pipehandler. Make sure the hinge pins are not loose due
to excessive wear in the bore of the clamp clevis or a broken
retaining bolt.
Inspect the link tilt intermediate stop and adjustment device for
overall integrity weekly. Replace the components if there is
excessive looseness of the threaded rod in the threaded hole of the
pivot arm (Figures 4-24 and 4-25). An indication of a possible
problem is if the two intermediate stops are not adjusted equally
(i.e., if the thread engagement differs between the two stops).
Failure to perform this inspection and/or component replacement
can result in injury to rig personnel.
Visual inspection
Use calipers on a regular basis to measure the amount of wear on
the elevator link eyes (Figure 4-1). Compare the measurements
with the Wear Chart (Figure 4-1) to determine the current
strength of the elevator links. The capacity of the links equals the
capacity of the weakest link.
4-14
Upper
Eye
(Hook)
;;;;
;;;;
;;;;
;;;;
Capacity
(per set)
in Tons
2 3/4 in.
2 9/16 in.
2 3/8 in.
2 3/16 in.
350
300
225
175
;;;
;;;
;;;
3 1/2 in.
3 1/4 in.
3 in.
2 3/4 in.
500
420
325
250
7 1/2 in.
7 1/4 in.
7 in.
6 3/4 in.
350
300
225
175
;;;;
;;;;
;;;;
A
Lower
Eye
(Elevator)
4-15
March 8, 2001
Landing collar
4-16
4-17
March 8, 2001
Drive stem
Regularly inspect and measure the drive stem/main shaft for wear.
Remove the drive stem/mainshaft from service if bore wear is
greater than the dimensions shown in Figure 4-2.
Determine inspection frequency according to API Recommended
Practice 8B, Section 2 for power swivels and power subs.
Varco recommends the use of API RP 7G and API RP 8B as
guidelines for interpreting and performing inspections.
Measurement techniques are specified in API RP 7G, Section 10.
Use API Bulletin 5T1 to identify and define imperfections found
during inspections.
Large Bore
1.30 Minimum @ Landing
Collar Grooves (2.45 New)
3.75
Diameter (New)
(1.70 New)
9.000
Diameter
Small Bore
1.30 Minimum @ Landing
Collar Grooves (2.45 New)
3.00
Diameter (New)
(1.70 New)
9.000
Diameter
4-18
3600000
3500000
3400000
3300000
3100000
New Condition
(3.82 Bore)
3000000
2900000
2800000
2700000
2600000
2500000
2400000
2300000
1.00
1.05
1.10
1.15
1.20
1.25
1.30
1.35
1.40
1.45
1.50
1.55
1.60
1.65
1.70
2200000
1.75
Load (Lbs)
3200000
4-19
March 8, 2001
4-20
I.A.D.C.
ASTM A-275
ASTM E-709
Ultrasonic Inspection
In addition to the MPI, Varco also recommends performing an
Ultrasonic Inspection of the above components to detect any
erosion of the inside diameter. Any erosion reduces the loadcarrying capability of the part. Any subsurface irregularity can
also compromise a components integrity.
Details on Ultrasonic Inspection procedures are in the
publication: ASTM A-388 Std. Practice for Ultrasonic Examination
of Heavy Steel Forgings.
Safety valve inspection procedures (IBOP)
4-21
March 8, 2001
4-22
Chapter 2
Lubrication
4-23
March 8, 2001
3. Repack the inside area with grease every six months (refer to
Figures 1-9 and 1-10 in the Description book).
4. Inspect the gears for corrosion or damage. Clean, lubricate or
replace components as required. There is a timing mark on
the gears to ensure correct orientation. If these marks are not
visible when removing the gears, mark the gears before
removal to ensure correct orientation when reinstalling them.
If there are problems shifting from one gear to the other, use the
following procedure to shift the gears:
1. Turn the drive stem with chain tongs to make sure the gear
mesh aligns properly. Do not turn the DC motor while
shifting gears.
2. Insert two 3/8 in. bolts in the threaded holes on the bottom
of the shafts while shifting the gears and use a bar to turn the
shaft in the proper direction. Do not shear the bolts.
Eccentric shaft rotation direction is the same as the shifter
input shaft when shifting into gear.
3. If the shift input mechanism slips when attempting to shift
gears, use a torque wrench to check the torque of the shifter
when the clutch begins to slip. If the torque is less than
65 ft lb, then use the Torque setting procedure to adjust the
clutch
4-24
4-25
March 8, 2001
Gear Subplate
Lower Gearcase
Detail A
4-26
4-27
March 8, 2001
Oil capacity
The TDS-4S holds approximately 10-20 gallons of oil, but oil
capacities vary according to the type of cooling systems, etc.
installed. Always fill the transmission to the middle of the sight
glass. Use the following procedure to fill the transmission for the
first time on a new top drive:
1. Fill the gearbox to the top of the sight glass
(approximately 10-20 gallons).
2. Operate the top drive 10-15 minutes and check the
sight glass.
3. The oil level should be near the middle of the sight glass.
If the oil level is below the middle of the sight glass, add more
oil until the level reaches the middle of the sight glass. If the
oil level is at, or above the middle of the sight glass, do not add
any additional oil to the gearcase.
After installation and initial operation of the top drive, always fill
the transmission to the middle of the sight glass.
When draining oil from the drain plug at the bottom of the
gearcase, only the 5-6 gallons of oil at the bottom of the gearcase
actually drains. Oil still remains in the rotating head cavity
(approximately 1-2 gallons), the oil lube/pump/cooler system
(approximately 1-2 gallons), and the wetted surfaces inside the
motor housing assembly (approximately 2-3 gallons). Removing
the suction hose from the cover plate below the pinion shaft
allows more oil to drain and also removes sediment that collects
there. Removing the oil drain plug from the rotating head allows
more oil to drain.
4-28
4-29
March 8, 2001
Grease
Fittings
Wash Pipe
Assembly
Bonnet
4-30
Grease
Fittings
Grease
Fitting
Grease
Fittings
Grease Fitting
Grease Fittings
4-31
March 8, 2001
4-32
Grease Fitting
(6 on IBOP Actuator
Rollers, Cylinder Pins
and Arm Pins)
Grease Fitting
(6 on Optional Link Stop
and Cylinder Assembly)
Grease Fitting
(1 each side of Torque
Tube on Clevis Pin)
Grease Fitting
(8 on Bottom of Clamp)
4-33
March 8, 2001
Master Bushing
Wear Guide
4-34
Open
Position
Actuator Shell
Grease Fitting
Crank Arm
Grease Port
Actuator Arm
Groove
Upper IBOP
Valve
4-35
March 8, 2001
4-36
4-37
March 8, 2001
Grease
Fitting
(20)
Grease Fittings
Grease Fittings
4-38
Grease Fittings
Grease
Fitting
(20)
Swing
Guide Dolly
Grease
Fitting
Grease
Fitting
Grease Fittings
4-39
March 8, 2001
Grease
Fitting
(28)
Grease Fittings
Grease Fittings
4-40
Bail
Bail Pin
Bail Pin
Grease Fitting
Grease Fitting
4-41
March 8, 2001
Transmission Cooler
4-42
Grease Fitting
Heat Exchanger
Grease Fitting
Heat Exchanger
4-43
March 8, 2001
Lubrication schedule
Frequency
Daily
Daily
Daily
Daily
Daily
Daily
Daily
Location
Bonnet seal
Torque wrench (PH-85)
Gearbox oil (check level)
Rotating head
Safety valve actuator cranks
Hydraulic pressure filter
Wash pipe assembly
Lubricant code*
1
1
2
1
1
Number of points
2
6
1
5
2
Each trip
Each trip
1
1
7
20
Weekly
Weekly
Weekly
Weekly
Weekly
Weekly
Weekly
Weekly
Weekly
1
1
1
1
6
4
7
4
3
3
Monthly
Monthly
3 months
3 months
3 months
AC blower motor
Change gearbox oil
Gear oil filter/suction strainer
1
2
2
1
1
4-44
Lubricant specifications
TDS-4S transmissions operate under a combination of heavy and
shock loads. Under these conditions oil tends to extrude out of
the gear mesh. Keeping an effective film of oil on the gear mesh
requires oil with an AGMA extra pressure rating, and a
minimum viscosity of 100 SUS at operating temperature.
Varco top drives also operate under a wide variety of
temperatures. Select lubrication for the TDS based on the
minimum ambient temperature to be expected before the next oil
change. Under all but the most severe operating conditions,
Varco recommends changing the oil every three months.
Introducing an oil viscosity greater than required by the ambient
temperature can:
Damage the gearbox due to reduced oil flow
Damage the oil pump because of excessive load
All oils change viscosity with temperature and EP oil is no
exception. The TDS transmission lubrication system is limited to
pumping oils of a maximum of 9,000 SUS viscosity.
Varco recommends measuring the oil temperature with a contact
thermometer. Measure on the pump discharge fitting on the TDS.
The following tables will aid in your lubricant selection and keep
your TDS-4S transmission operating properly:
Minimum ambient temperature
F
C
Varco P/N
Below 20
-6
20 to 60
-6 to 16
2EP, ISO 68
56004-1
45 to 85
7 to 30
56004-BSC
Above 70
21
56004-2
4-45
March 8, 2001
Ambient
temperature
range
Gear Oil
Above
-4F
(-20C)
Below
-4F
(-20C)
Above
70F
(21C)
45 to 85F
(7 to 30C)
20 to 60F
(-6 to 16C)
Castrol
MP grease
Alpha LS-320
Alpha -150
Alpha LS-68
Chevron
Avi-Motive
Avi-Motive W
NL Gear 320
NL Gear 150
NL Gear 68
Exxon
Lidok EP2
Lidok EP1
Spartan EP320
Spartan EP150
Spartan EP68
EP Lube HD320
EP Lube HD150
EP Lube HD68
Gulf
4-46
Mobil
Mobilux EP2
Mobilux EP1
MobilGear 632
MobilGear 629
MobilGear 626
Shell
Alvania EP2
Alvania EP1
Omala 320
Omala 150
Omala 68
Statoil
Uniway EP2N
Uniway EP1N
Loadway EP320
Loadway EP150
Statoil
Texaco
Multifak EP2
Multifak EP1
Meropa 320
Meropa 150
Meropa 68
Total
Multis EP2
Multis EP1
Carter EP 320
Carter EP 150
Carter EP 68
Union
Unoba EP2
Unoba EP1
NGLI
AGMA
6EP
4EP
2EP
ISO Viscosity
Grade
320
150
68
Ambient
temperature
range
Motor Grease
Hydraulic Oil
Bio-degradable
All
temperatures
14 to 185F
(-10 to 85C)
5 to 167F
(-15 to 75C)
N/R
Hyspin AWS-46
Hyspin AWS-32
Black Pearl
AW Hyd oil 46
AW Hyd oil 32
Exxon
N/R
Nuto H46
Nuto H32
Gulf
N/R
Harmony 46AW
Harmony 32AW
Mobil
N/R
DTE 25
DTE 24
Shell
N/R
Tellus 46
Tellus 32
Statoil
N/R
Hydraway HMA 46
Hydraway HMA 32
Texaco
N/R
Total
N/R
Azolla ZS 46
Azolla ZS 32
Union
N/R
Unax AW46
Unax AW32
NGLI
AGMA
ISO Viscosity
Grade
46
32
Castrol
Chevron
4-47
March 8, 2001
4-48
Chapter 3
Maintenance
Adjustment procedures
Adjusting the torque wrench
Use the following procedure to adjust the pipehandler torque
wrench:
4-49
March 8, 2001
Make/Break
Valve
Recycle
Sequence
Valve
Clamp
Sequence
Valve
Torque
Sequence
Valve
Torque Wrench
Manifold
BREAK
MAKE
Hydraulic
Pressure
Return
RECYCLE
CLAMP
TORQUE
PRV
50
60
40
30
1000
1500
70
80
Hydraulic
Pressure
Inlet
20
LIFT LOWER
500
2000
90
10
0
PSI
Ft.Lbs.
Torque Gauge
0 - 2500 PSI
2500
x1000
10
0
Lift/Lower
Flow Control
Valve
4-51
March 8, 2001
4-52
Needle Valve
(on opposite side)
Pressure Reducing
Valve
Pressure
Gauge
4-53
March 8, 2001
4-54
Alignment Cylinder
Lug (ref)
Pressure Reducing
Valve
Needle Valve
Alignment
Cylinder
Manifold
Accumulator
Bracket
Gas Valve
4-55
March 8, 2001
Needle Valve
Alignment Cylinder
Valve Manifold
Bracket
Gas Valve
Accumulator
4-56
Motor Alignment
Cylinder
Shipping
Brace
Motor
Frame Dolly (Ref)
4-57
March 8, 2001
4-58
4-59
March 8, 2001
Precharging the
counterbalance system
Please read these instructions completely before precharging,
making note of the special cautions at the end of the section.
1. Use an inert gas such as nitrogen for precharging
accumulators. If oil-pumped is not available, use dry, waterpumped nitrogen gas.
2. Before precharging, make certain:
a. The accumulator end caps are screwed flush into the
accumulator body.
b. The gas valve is screwed in tight.
c. No oil remains trapped in the top end of the accumulator.
3. Remove the gas valve protector and the gas valve cap.
4. Attach the charging hose to the nitrogen bottle and to the gas
valve using the following procedure:
a. Use thread sealing and lubricating compound on the pipe
threads of the gauge.
b. Back the gas chuck stem completely out of the way before
attaching the assembly to the accumulator gas valve.
c. Use a wrench to tighten the gas chuck swivel nut onto the
gas valve. Close the bleeder valve.
d. Turn the gas chuck stem all of the way down, depressing
the core in the accumulator gas valve.
e. Only crack open the nitrogen bottle valve to slowly fill the
accumulator. Shut it off when the gauge indicates 900 psi.
f. If the 900 psi precharge pressure is exceeded, make sure
the nitrogen bottle valve is closed, then open the bleeder
valve (opposite the gas valve below the gauge) slightly, but
only momentarily, to reduce pressure.
g. Before loosening the swivel nut, turn the gas chuck stem
out all of the way, then open the bleeder valve.
h. Prevent the gas valve from turning, loosen swivel nut, and
remove the assembly.
5. When precharging is complete, replace the cap on the gas
valve and install the gas valve protector.
4-60
4-61
March 8, 2001
4-62
Torque Tube
V
a
r
c
o
Torque Cylinders
4-63
March 8, 2001
Clamping Jaws
Body
Stabbing Guide
4-64
Mounting Shaft
Frame
Safety Valve
Actuating
Cylinder
(2)
Vertical
Positioning
Cylinder
Hanging
Height
Adjustment
Guard
4-65
March 8, 2001
4-66
Frame
Mounting
Shaft
Safety Valve
Actuating
Cylinders (2)
Vertical
Positing
Cylinder
Safety Valve
Actuating
Arm (2)
Torque
Tube
Stabilizer
Stop Tube
Hanging Height
Adjustment Shim
Torque
Tube
Guard
Body
Torque
Cylinder (2)
Stabbing
Guide
Clamping
Jaws (2)
Clamping
Cylinder
Piston
Control
Manifold
4-67
March 8, 2001
P/N
72219
72220
72221
Description
Piston seal
Rod seal
Rod wiper
Disassembly
1. Remove the slotted hex nut and cotter pin attaching the two
halves of the stabbing guide together at the front and swing
the guides out to each side.
2. Vent the clamping cylinder as follows: disconnect the
hydraulic lines to the clamp port and front unclamp port on
the clamp body cylinder at the torque wrench manifold clamp
and unclamp ports.
4-68
3. Remove the jaw pins from the rear clamping jaw and remove
the jaw.
4. Remove the two screws holding the jaw spacer to the front
clamp cylinder piston and remove the spacer and jaw spacer.
5. Remove the two screws holding the clamp clevis to the rear
clamp cylinder piston.
6. Remove the pins holding the clamp body to the clamp clevis
and remove the clamp clevis. Be sure to remove the spacer
from the piston rod slot.
7. Push in the cylinder gland from the rear cylinder head
retainer ring and remove the ring with a screwdriver.
8. Attach the sliding hammer to the rear piston rod and carefully
pull the piston until the cylinder gland can be removed.
9. Continue to pull until the piston comes out.
10. Using a piece of wood or brass bar, tap the front clamp piston
from the front and remove it from the rear.
11. Remove and discard the piston seals, rod seals, and rod
wipers.
12. Remove the front piston rod seal and rod wiper from the
clamp cylinder body and discard.
13. Inspect the clamp cylinder bore thoroughly for dirt, burrs,
nicks, gouges, and pitting. Repair and clean as necessary.
Assembly
1. Insert a new front rod seal and rod wiper in the clamp
cylinder body and lubricate with clean hydraulic fluid.
2. Install a new piston seal in the front piston groove and
lubricate with hydraulic fluid.
3. Insert the front piston into the clamp cylinder body with the
two jaw spacer screw holes orientated vertically.
4. Gently and evenly tap the piston into place until the rod
appears beyond the front cylinder bore.
4-69
March 8, 2001
4-70
Cam
Stationary Flange
Cam Follower
Locking Lever
Auto-Return
Cylinder
Torque Arrestor
Location
Glyd Ring (8)
Swivel Block
Torque Wrench Hanger
(Lug not shown)
4-71
March 8, 2001
Disassembly
Cam Assembly
Locking Handle
Return Cylinder
Return
Cylinder
Clevis Pin
Return
Cylinder
Rod End Detail
Hex Nut
;;;;
Cotter Pin
Cam
;;;;;;
;;;;;;
;;;;;;
;;;;;;
C;;;;;;
;;;;;;
;;;;;;
;;;;;;
Cylinder Clevis
Excluder
Cap
Detail
Retainer Ring
Ball Bearing
Glyd Ring (8)
Excluder Cap
Gasket
Cam
Ball Bearing
C
Stationary Flange
Bull Gear
Lip Seal
4-73
March 8, 2001
Assembly
1. Lubricate the eight new glyd rings with hydraulic fluid and
insert them into the glyd ring grooves inside the rotating
block.
2. Place the excluder cap and gasket on the bottom of the
rotating block.
3. Using a tugger or other support, carefully mate the rotating
block to the stationary flange.
4. Reinstall the ten hex-head screws and torque to 250 ft lb.
5. Safety wire the screws per standard safety wire procedures.
6. Reinstall the quick disconnect hydraulic fittings on the
rotating block.
7. Attach the return cylinder rod to the clevis with the clevis pin
and install the slotted hex-head nut and cotter pin.
8. Reinstall the pipehandler components per the procedures
detailed in the Installation and Commissioning book.
4-74
4-75
March 8, 2001
15. Support the rotating block and remove the ten screws.
16. Remove the rotating block and glyd rings.
17. Remove the excluder cap and gasket.
18. Remove the glyd rings from the rotating block and discard.
19. Remove excluder cap gasket and replace with new gasket.
Assembly
1. Lubricate the eleven new glyd rings with hydraulic fluid and
insert them into the glyd ring grooves inside the rotating
block.
2. Place the excluder cap and gasket on the bottom of the
rotating block.
3. Using a tugger or other support, carefully mate the rotating
block to the stationary flange.
4. Reinstall the ten hex-head screws and torque to 250 ft lb.
5. Safety wire the screws per standard safety wire procedures.
6. Reinstall the QD hydraulic fittings on the rotating block.
7. Reinstall the hydraulic motor assembly.
8. Reinstall the pipehandler components per the procedures
detailed in the Installation and Commissioning book.
4-76
Disassembly
1. Disconnect the air hose from the rotating head rotating block
to the link tilt assembly.
2. Support the link tilt and remove the two upper and two lower
screws attaching the link tilt to the link adapter.
3. Lower the link tilt to the floor with the air actuator to be
replaced facing up.
4. Remove the cotter key and pin from one end of chain
connecting the two sealing plates.
5. Remove the safety wire from the four hex-head cap screws
holding the air actuator sealing plate to the link tilt base or
lever and remove the screws.
6. Lift the lever or base off the air actuator sealing plate, and
rotate it 180 on the link tilt pivot pin and lay down.
7. Remove the nuts and washers holding the sealing plate to the
air actuator and remove the plate.
8. Using a pry bar or screwdriver, pry the air actuator away from
the screws, attach the actuator to the hanger plate and remove
the screws using a hex wrench.
9. Remove and discard the air actuator.
10. Remove any burrs or gouges on sealing surfaces of the hanger
and sealing plates.
4-77
March 8, 2001
Lever Weldment
Pivot Pin
Sealing Plate (2)
Nuts, Lock
Washers (18)
Pressure
Regulator
Air Actuator
Base
Sealing Plate
Bolt (4)
Quick
Exhaust
Valve
Lever
Intermediate
Stop (2)
Connecting Chain
Buttonhead
Capscrew (18)
4-78
Lever Weldment
Pivot Pin
Sealing Plate (2)
Nuts, Lock
Washers (18)
Pressure
Regulator
Hanger Plate
Air Actuator (2)
Sealing
Plate
Bolt (4)
Base
Quick
Exhaust
Valve
Lever
Intermediate
Stop (2)
Connecting Chain
Stop Pivot Arm
Elevator Link (Ref)
Stop Release
Loop
4-79
March 8, 2001
Assembly
The air actuator has aluminum neck bead rings on both sealing
surfaces. These beads must be compressed equally to ensure a good air
seal. This requires more than one tightening pass to accomplish.
Over-torquing may cause hex sockets to strip.
4. Torque the cap screws to the hanger plate at 80 ft lb.
5. Insert the 18 bolts into the neck ring of the air actuator.
6. Reinstall the air actuator sealing plate, coat the bolt threads
with locktite and fasten with the lockwashers and nuts
provided.
7. Torque the nuts to the sealing plate at 80 ft lb.
(See Caution above.)
8. Lift and rotate the link tilt lever or base to line up with the air
actuator sealing plate. Attach with the four hex-head cap
screws and torque to 250 ft lb.
9. Safety wire the four screws.
10. Reconnect the chain between the two sealing plates.
11. Reinstall and adjust the link tilt per the Installation and
Commissioning book.
4-80
Rear jaw
1. On the rear jaw, remove the cotter pins from the retaining
bolts and slotted nuts.
2. Support the retaining bolt while removing the slotted nut.
3. Remove the retaining bolt from the piston jaw.
4. Support the remaining retaining bolt while removing the
slotted nut and upper die retainer.
5. Remove the retaining bolt and lower die retainer.
6. Remove the tong dies from the jaw.
4-81
March 8, 2001
Rear jaw
1. Loosen the socket head cap screws securing the jaw assembly
to the piston.
2. Support the jaw assembly and remove the socket-head cap
screws and washers from the jaw assembly and piston.
3. Remove the rear jaw assembly from the piston.
4-82
4-83
March 8, 2001
Disassembly/assembly of the
drilling motor and motor support
bonnet
1. Remove the upper bearing cover and grease seal
(Figure 4-32).
2. Pressurize the air brake to hold the drive mechanism in place.
3. Remove cotter pins, slotted nuts and the rotating head.
4. Remove the lower gearcase, carefully avoiding damage to the
lower gearcase locator dowel pins.
5. Carefully remove the bull gear, avoiding damage to the
bearing surfaces or wear sleeves. Do not remove the gear from
the shaft unless you are replacing it.
6. Remove the pinion seal and retaining ring.
7. Remove the main body.
8. On the opposite end of the motor, remove the magnetic
pickup and brake cover.
9. Remove the brake for service.
4-84
Main Body
Air Brake
Low
Gear
Assembly
DC
Drilling
Motor
Bull Gear
High
Gear
Assembly
Pinion Gear
Manual
Shifter
Input
Geneva
Mechanism
HI
Shaft
LO
Oil Level
Sight Glass
Motor
Pinion Seal
Lower Gear
Case
Motor
Alignment
Cylinder
Gear
Selection
Indicator
4-85
March 8, 2001
4-86
Torque Chart
Motor support/bonnet to main body
Main body to motor support/bonnet
Bull gear to hub
Lower gearcase to main body
Rotating head to lower gearcase
Brake adapter ring to motor
Brake to brake adapter plate
Brake drum to hub
Brake cover to brake
1100 ft lb
1100 ft lb
580 ft lb
250 ft lb
250 ft lb
250 ft lb
50 ft lb
250 ft lb
50 ft lb
4-87
March 8, 2001
5. Make sure the fixture is clean and the horse shoe face and
bar are parallel.
6. Place the fixture on the motor shaft with the horse shoe end
against the inner face of the gear and the bar against the outer
face of the gear, sandwiching the pinion gear in the fixture.
7. Adjust the adjusting screw to butt against the end of the
motor shaft.
8. Attach a calibrated dial indicator gauge to the fixture and set
to zero.
9. Back off the adjusting screw until the gauge reads 0.0720.074 in. Then lock the screw in place with a locknut.
10. Remove the fixture from the pinion gear assembly.
4-88
4-89
March 8, 2001
Axial Fan
20 hp
Blower Motor
Transmission
Cooler
Locking Key
Oil Fittings (2)
Blower Housing
Gasket
Mounting
Brackets (2)
Blower Impeller
Taper Lock
Bushing
Gasket
Flex Duct
Connection
Point
Mounting Plate
Blower Duct to
AC Drilling Motor
Spark Arrestor
4-90
4-91
March 8, 2001
4-92
Dual Shaft
20 hp AC
Blower Motor
Blower Mount/
Brake Cover
Blower
Housing (2)
Impeller (2)
8 in. Flex
Connection (2)
Water
Connections
DC to Motor
Exhaust Port on
Upper Gear Case
Inspection
Cover
GE
Drilling Motor
Heat Exchanger (2)
4-93
March 8, 2001
4-94
n
n
4-95
March 8, 2001
1
2
4-96
Do not nick the wire with the edge of the hole in the fastener.
Position the safety wire so the pull exerted by the wire tightens the
nut. For best results, let the wire leave the fastener in a clockwise
direction
Twist the safety wire so the loop around the bolt or head has
sufficient tension to keep it from slipping up and over the
bolt head, with resulting slack in the safety wiring.
When securing castellated nuts with safety wire, tighten the nut to
the low side of the selected torque range, unless otherwise specified.
If necessary, continue tightening within specified torque limits
until a slot aligns with the hole.
The number of nuts, bolts or screws that can be safety-wired
together depends on the application. As a guide, when safetywiring widely spaced bolts by the double-twist method, a
group of three, or a 24 in. (610 mm) length of safety wire is
usually the maximum.
4-97
March 8, 2001
4-98
Chapter 4
Troubleshooting
Probable cause
Remedy
Replace seals.
Clean or replace.
4-99
March 8, 2001
Probable cause
Remedy
Alignment cylinder
fails to move
transmission at
trunnion pivot points
with recommended
pressure setting.
Replace seals.
Excessive motor
movement.
4-100
Probable cause
Remedy
Clean or replace.
Troubleshooting the
retract guide dolly
Symptom
Probable cause
Remedy
4-101
March 8, 2001
Probable cause
Remedy
Gearbox temperature
is excessive.
Oil is foaming.
Replace oil.
Oil level too low or too high. Adjust oil level to recommended
level in sight glass.
Incorrect lubricant used.
4-102
Probable cause
Remedy
Defective or improperly
adjusted pressure switch.
4-103
March 8, 2001
Probable cause
Remedy
Mechanical noise in
blower.
Loose impeller.
Replace as needed.
Blower runs
intermittently.
DC MOTOR
OVERHEATING,
OVERTEMP alarm
stays on with blower
running.
4-104
Symptom
Probable cause
Remedy
DC MOTOR
OVERHEATING,
OVERTEMP alarm
stays on with blower
running.
WATER
DETECTOR
alarm is on
(closed loop system).
4-105
March 8, 2001
Probable cause
Remedy
Readjust.
Improper component or
component installation.
4-106
Improper saver sub length or Saver sub length too long. Sub
machining.
should also have proper chamfer on
both shoulders.
Symptom
Probable cause
Tool goes up, clamps, Air pilot valve on counterbalance manifold stuck or
and cycles, but
inoperative.
remains clamped on
pipe when switch is
released.
Remedy
Remove air supply line to verify air
supply when solenoid valve is
activated.
Connection overtorqued.
4-107
March 8, 2001
Troubleshooting the
safety valve actuator
Symptom
Probable cause
Remedy
Probable cause
Remedy
Improperly adjusted.
4-108
Probable cause
Remedy
Improperly connected
QDs.
4-109
March 8, 2001
Troubleshooting the
crown height indicator
Symptom
Green power indicator
does not illuminate.
Probable cause
Remedy
No AC power being applied. Check Expo purge system and
input AC power.
Internal AC breaker tripped. Check internal circuit breaker on control
electronic module for tripped condition.
Failure of DC power supply. Check AC power LED on control electronic
module. Replace electronic control module
necessary.
Replace electronic control module.
Depressing the PUSH TO Malfunction of control
electronics.
TEST indicator does not
cause position indicators to
flash or illuminate.
Misadjusted lower sensor
Check proximity switch alignment.
Yellow indicator is
proximity switch.
constantly illuminated
while traveling assembly is
below ten feet.
Defective lower sensor
Check mechanical operation of sensor
bracket assembly.
bracket assembly.
Perform cable continuity tests.
Defective sensor cable
between sensor junction box
and control electronics.
Defective proximity switch. Replace proximity switch.
Malfunction of electronics
control module.
Misadjusted lower sensor
proximity switch.
Malfunction of electronics
control module.
4-110
4-111
March 8, 2001
4-112
TDS-4S
Top Drive
Drilling
System
Control System
SM00620-5
March 8, 2001
5-2
Contents
TDS-4S Control System
General description .......................................................... 5-5
Maintenance and troubleshooting/
checkout procedures ........................................................ 5-7
5-3
March 8, 2001
5-4
TDS-4S
Control System
General description
The Top Drive Drilling System (TDS) typically operates from the
same SCR as the rotary table. A panel, located in a Central
Electronics Enclosure (CEE), switches power from one to the
other. The CEE typically contains the following components:
DC contactors
A programmable logic controller (PLC)
Auxiliary AC components
Rig instrumentation interfaces for recording
TDS torque and speed
5-5
March 8, 2001
In dedicated top drive SCR configurations, the SCR runs the top
drive only.
The panel can feature a purge control system so it can be located
in hazardous areas. If the panel is located in the SCR room, a
purge system is not required.
The panel is designed to be compatible with all presently installed
SCR systems and is configured at installation for the specific SCR
used on a rig. Logic and alarm functions are connected to the
TDS via PLC programming so the TDS can operate existing rig
systems. Also, TDS interlocks and limits, such as spin-up and
makeup speeds, are programmed into the PLC and are the same
for all installations.
5-6
Procedure
Frequency
Indicator lamps
Heater
Monthly
Monthly
Monthly
Component mounting
Monthly
Monthly
Weekly
Monthly
Every 3 months
5-7
March 8, 2001
5-8